Method of manufacturing turbine-buckets.



E, H. FARQUHAR. METHOD OF MANUFACTURING TURBINE BUGKBTS.

?atented()ct.27,l908.

APPLICATION FILED JAN. 2, 1906. 901,960.

2 SHEBTSSHEET 1.

E. H PARQUHAR. METHOD OF MANUFAGTUBING TURBINE BUOKETS.

APPLIUATION FILED JAN. 3, 1906. 901,960, Patented 960211908.

2 SHEETS-SHEET 2.

mvantor":

Witnesses:

X 74? Edmund Hfarquhar,

UNITED STATES! PATENT osmcu.

fumi'uivn n. FARQUl-lnlt, or sonnivucranr, NEW YORK, Assieuon TO omen/it smac'riuc COMPANY, A. CORPORATION OF NEW YORK.

METHOD OF MANUFACTURING TURBINE-BUGKETS.

Specification of Letters Patent.

Patented Oct. 2?, 190a.

Ayplication filed January 2, 1906. Serial No. 294,182.

if?) all, whom it may concern: Be it known that, Llfimiuun ll. Farrow-mu,

amuincn of the United States, residing at Schenectady,- couuty of Schenectady, State of New York have invented certain new and useful, Improvements in Methods of Manuiaoturing Tll1b1!l6-Bl1Ck8tS, of which the following is a specification.

buckets into a base whereby uniform and satisfactory results may be obtained by the class of workmen oro narily employed in foundries and machine shops.

In the manufacture of buckets for elasticfluid turbines, it is of the utmost importance that the individual buckets shall be firmly cured to their u support on account of the great stress to which they are subjected, that the buckets shall be accurately alined top and bottom, that the inlet and discharge angles shall'be in exact accordance with the theoretical angles therefor, and that the height, pitch and location of the bucket with respect to the base shall be in exinruaecordance with the specifications and drawings therefor.

In carrying out my invention 1 make the buckets out of a suitable alloy that capable of being readily worked, is capable ot' receiving' a smooth finish on its faces, is suiiiciently hard to prevent the strain] or other motive fluid from cutting it excessively, is non-corrosive, and one that will not rust or otherwise be injured by the motive-fluid. Experience has demonstrated that lJLK h'Oi'J-S made out of a hot rolling alloy are satisfactory for the purpose. 1 meter to make the base with which the buckets are united out of an alloy which possesses the necessary strength, is easy to work, will make a good union with the buckets, and requires a relatively moderate temperature in casting. Where the base is made of an alloy'ha ving the same or substantially the same characteristics a1 .a buckets, it will. generally be satisfactory.

I find it desirable to pass the bucket stock through swaging dies after it is received from the extruding dies or other means for forming it in order that the dimensions may be more nearly correct. 'lhi, also has the advantage of giying a somewhat bcttcr suu face to the buckets. W'hcrc the bucket stock is sullicienlly close to dimensions for practical purposes the swag'ing' may be omitted.

The buckets as now formed by the extruding dies have the proper shape in cross-sec tion except that they are not sharp enough at the inlet and discharge edges, and are not of the right width. I therefore take each bucket, cut it to the proper. length and dress the edges until the bucket has the proper width, and sharpen the edges. The dressing and sharpening are preferably done by a single operation, as by the use of a milling machine having two rotary cutters acting simultane ously on opposite sides of the bucket. 'When the buckets are to be provided with a cover the ends adapted to receive it are formed by milling or otherwise with suitable tenons, either round, square or substantially so, or of other suitable shape.

The preferred method of procedure in a foundry is to pour the metal at a uniform or substantially uniform temperature, and where structures are being made with buckdili'ering considerably in their cross sectionalarea, it follows that unless special means are provided, some of the buckets of large cross-secti0n may not be thoroughly united to the cast-metal base owing to chilling, while others with smaller cross-section may be overheated to such an extent as will render them worthless; and in this connection it must be borne in mind that if one bucket is not properly united or is in any Way injured it will result in discarding the whole bucket segn'ient. "To prevent the above objections and to permitof the foundry using metal at a uniform or siibstanlially uniform temperature for all buckets without regard to their cross-section, l form the base ends of all of the buckets so that they will presei'lt the same or substantially the same cross-section to the nwlteu-melal. This elm be done by decreasing the amount ofmetal in the base ends of the buckets, by slotting. The buckets need not in all cases be so treated; this being governed largely by the size of the buckets and the tem 'ierature of the metal used. The slot is of suitable size and shape to meet the requirements. In some cases I find it advantageous to make the slot substantially rectangular with parallel walls and in other cases with side walls forming a dove-tail groove or opening so that there is a mechanical securing of the parts in addition to that due to the fusing or uniting of the metals forming the buckets and base. By increasing the size of the slot in large buckets and decreasing it in the small, uniform results can be obtained Without changing thetemperatu're of the moltenmetal and Without danger of defective structures. The next step is to prepare the mold. Mounted on the follow board is a block of suitable shape to form a chamber in the mold to receive and position a core which'is inserted at a later stage of the process after the block has been removed. 'ln the top of the block which is preferably of metal, is a shallow groove arranged to receive the ends of the individual buckets. Between the buckets and engaging the base and side Walls of'the groove and also the buckets, are space blocks which determine the proper pitch of the buckets. In addition to this they deter mine the proper inlet and discharge angles of the buckets. A crown. is then applied to the upper ends of the buckets, the said crown being provided with notches, grooves, or

other equivalent devices registering with the tenons, and preferably, but not necessarily,

with guiding pins or equivalent devices serving to direct the tenons into their proper places. These pins are desirable because they save time in mounting the crown in place. The buckets may then be alined with'u gage to insure their occiniiying the proper position. in the present case they stand radially. The crown is then clamped in place. The block and crown constitute in efiect a frame for holding the buckets, and it is evident that the constniction can be varied Without departing from the invention. Preferably, but not necessarily, the

'block is provided with a. gate or runner.

Molding sand is then packed around the block and between the buckets. The drug or nowel. is then mounted on the, tollowboard and a certain amount bf sand added and rammed. Ator about this stage the crown is removed and the drag or nowel completely filled with sand and rammed. After it is suitably surfaced on the top a cover is clamped thereto and the mold reversed. The follow board is then removed exposing what- Was the under side of the block, and the sand covered with charcoal or other parting 59' medium. The cope is then placed in position with means for forming the sprue and one or more risers where such devices are necessary. The cope is then filled with sand and rammed and the sprue and risers removed. The cope is then removed exposing These are I buckets. I This leaves the ends of the buckets projecting a certain predetermined distance through. the sand. The mold is then slicked if necessary and otherwise treated to keep it in shape, After themold is completed it is put in an oven and baked for a predeten mined length of time at a given temperature. This dries out a certain amount of moisture senses and makes the mold. hard enough to insure a good casting without cutting. The next. step is to insert the core and replace the cope, when the mold is ready for service. Ivl etal at the proper temperature is poured into the mold. which fuses with the buckets and the whole becomes an integral mass. after which it is allowed to cool. Q1: moving the casting and the attached lnickets, the gate and sprue are cut off in the ordinary manner and the casting dressed to the proper din'icnsions and provided with one or to a wheel or other support. 7

If desired the bucket segment may be tested before finishing by striki. each ol. the buckets a light blow to ascertain whether or not the buckets are properly united with the base. Such action will cause the buckets having defect" union with the base to give ell a ditlcr from those having a-perfect union. it the casting is little rough at. the roots of the buckets it may be smoothed by a suitable llOOl. D

The final is to place the cover over the ends of the buckets and rivet over the ends of the tenons.

In the acconipui\ying (-rawin which iiiustrate one means by which my invention can be practiced; l igure l is a perspective view of a bucket segment with part of cover removed therefrom; Fig. :2 is a spective view of a section of the bucket stock as received from the extruding dies; Fig. 3 is a perspective view of a bucks ready to be inserted in the mold; Fig. i is a detail view showing a dovetail slot in the base end; Figs. 5 and 6 are detail views of further modifications in this particular, Fig. 7 is an inverted plan view of the crown used to hold the outer ends of the buckets while in the mold; Fig. 8 is section taken on line 9 9 of view of the follow-board with the arch shaped blockmounted thereon; Fig. 1.0 is a perspective View of the drag or n oivel after tho and block have been removed; and Fig. 11 is a perspective of one of the spacing devices.

thebase and forming an integral part thereof. In Fig. 18 shown the bucket as reor cut to the required length.

In Fig. 3 are shown the buckets after they are dressed and ready for use. ()11 the outer more holes for bolts where needed to secure Fig. 7; F 9 is a perspective it has been inverted and the follow board ceived from the dies and before it is dressed.

end of the bucket is a tenon 3 for securing In Fig. l, 1 represents the cast-metal base and 2 the separately formed buckets (Z1153, into i itely disposed holes mayfhe 'ptjovidetlas in 1 6. v l i1 Fig/7 is shown in inverted plan the, crown 13 for holding the upper en" s of the buckets. Projections 14 are'fortnedon'adjacent surfaces of the longitntlinalmembers 15, and between said projections are slots or rooves to receive the tenons and hold the nckets. Each longitudinal member, is providedwith a row of tapered-pins 16 which, when the crown is lowered into place, engage the ends ofthe buckets and direct the 'tenons into the spaces between the projections.

, In Fi 9, 17 represents the follow-board, and 18 t e block containing ashallow groove 19 on its upper face to receive the buckets 2 and the removable spacers 20. The crown 13 is provided with a longitudinal slot 21 through which the tenons on the buckets can be seen. The crown is held in place by clamps 22 that enter the block 18.

i 23 represents the gate or runner Iwhich may be attached to the block or be separable therefrom.

extending through the sand. In the illustration the block and crown are segments: of circles ofdifl'erent diameters, but they can be made straight and bent afterwards, if desired, although this is not so satisfactory as it requires an additional operation.

I have described the various steps in the process in the order which I have found to be most satisfactory, but it is evident that the order of the steps can be changed somewhat and also that some of those of minor importance can be omitted where the requirement" as .to the final product are not so severe as those mentioned. Y The means or apparatus for casting the o l l buckets into the base is not claimed herein because it forms the subject-matter of my divisional application Serial No. 356,763, tiled Feb. 11, 1907, in compliance with the requirement for division made by the U. S. Patent- Oliice under the provisions of Rules 41 and 42 of Olfice practice. XV hat I claim as new and desire to secure by Letters Patent of the United States, is,

l. The method of manufacturing bucket segments twhich consists in forming the buckets to thcJ desired dimensions, mounting the buckets a one end in a holder to space them apart and preserve their alinement, mounting a second holder adjacent the other ends of the buckets to space and aline them, securing the buckets by suitable means against longitudinal movement in the holders, placin g the buckets so prepared and arranged in a nowel and packing molding sand round one of the holdersand between the buckets tosu port and position them therein, releasnw t c securing means to permit a holder to be removed from the ends of the buckets,

In F' 10 is shown the drag with the cope holder and between the buckets,

completing the nowel, reversing it. formingthe cope, separating the flask, 1: moving the lastmentioned holder to expose the ends of the buckets and to form a space in the mold to receive the molten metalwhich forms the supporting member of the series of backets composing the segment, the ends ot the buckets projecting from the sand into said space, closing the mold and pouring molten metal into said space round the ends of the buckets, the temperature of the metal being such as to cause a fusion between it and the ends of the buckets.

2. The method of manufacturing bucket segments which consists in cutting the buckcts to the desired length, forming a tenon on one end, sharpening the edges, mounting the other ends of the buckets in a device to space them apart and aline them, mounting a secondspacing device on the tenons, clamping, the buckets between the two devices, rannning molding sand around said devices and between the buckets, removing the first device to expose the ends of the buckets, and pouring molten metal into the mold arohnd said ends, the temperature of the metal be-.

ing sutliciently great to cause fusion with the buckets.

3. The method of manufacturing bucket Segments which consists in forming tbebuck- (its to the desired din'lcnsions, mounting both endsof the same in holders to space them anthpreserve their alinemcnt, securing said holders against movement longitudinally of the buckets, ramming molding sand around the buckets, remm-ing the holders leaving the ends of the buckets exposed, bakingthe mold to harden it, and pouring molten metal. around the exposed ends of the buckets.

at. The method of manufacturing bucket segmentswhich consists in forn'iing the buckets to the required dimensions, reducing the cross-sectional area of the ends of the buckets to be exposed. to the molten metal, mounting one end of the buckets in a holder to space them apart and preserve their alinement, mounting a second holder on the other ends of the buckets to space and aline them, clamping the buckets between the two holders, packing moldingsand around the first removing the holders, completing the mold, and pouring molten metal around the exposed ends of the buckets, the temperature of the metal being such as to cause a fusion between it and the buckets Without injuring the sharpened edges of the buckets.

5. The method of manufacturing bucket segments which consists in forming the buckets to the required dimensions, mounting the buckets in a grooved block, inserting spacers between the base ends of the buckets, mountmg a crown on the opposite ends of the buckets to preserve the alinement of the buckets at'that point, packing sand around the flask, removmg the vidual spacers, inserting the flask and. pouring molten metal into the securing the buckets at their suitable means ogeinst longitudinal movement, paekmg sand. around theouckets and Saul dBVlCC, remoa'n'lg the securmg means and fihmg the mold, reversmg the Took},

the ouckets'and 'blook, removing the crown l forming the cope, SLPHTEHLUQ the parts of and. 'filling'themold to cover the exposed ends of the buckets, reversing the mold, forming" the cope, separating the parts of block and the indithe core and closing the flask, removing the spacing device, 111- sert'ing the coxe, closing the flask, and pourmold of sueh temperature that it will {cause 1 ing molten metal at a suitable temperature a fusion with'the bucket bases Without ininto-the mold. juring the shmfpened edges. v In Witness whereoi 6. The method of manufactuying bucket 1 hand this 30th day of December, 1905. segments which consists in fogm'mg the buck- EDB'IUND FARQUHAR.

ets to the required dimensions, 'mounting'i Witnesses: U one end of the buckets m a spaemg (16V1C3,' BENJAMIN B. HULL,

1 other ends by l HELEN Omoen.

I have hereunto set my 

